Volume 5, Issue 5, May – 2020
ISSN No:-2456-2165
A Synonymous Description of Al-Zn
Alloy in Different Casting Process
Chethan V
M. Tech Scholar
Department of Mechanical Engineering
Nagarjuna College of Engineering and Technology
Bengaluru, Karnataka, India
Abstract:- Last few decades rapid increase of utilization
of Aluminum-zinc alloys, particularly in the area of
automobile and aeronautical sector due to
characteristics of high strength to weight ratio, low
density, high wear resistance and low coefficient of
thermal expansion. These advancements in the field of
application is the motivation to study of their
mechanical and microstructure important properties
such as density, tensile, hardness and wear behavior.
In this paper, Aluminum based alloys containing
10%, 20% and 30% weight of Zinc were synthesized
using casting method by using As cast and centrifugal
casting. To study the Compositional analysis of
Microstructure and Mechanical properties different
samples of same composition shows near uniform
distribution of zinc in the prepared alloys. The
performance of the microstructure shows the presence
of primary zinc. The performance ids studied using
Tensile, resistance to wear, Hardness and density test
methods. Tensile tests were carried out using universal
testing machine. Wear Test behavior was studied by
using computerized pin on disc wear testing machine. In
both the testing cases it is observed that for all the tests
such as tensile strength, Resistance to wear, hardness
and density better performance with increase in Zinc
percentage.
Keywords:- Aluminum-zinc alloys, Tensile test.
.
I. INTRODUCTION
Rapid development of Automobile, Marine and
aeronautical industry the importance of research and
development activities on composite materials become
common practice. From past few decades most of the
traditional materials are replaced by composite materials
due to its superior properties such as higher specific high
hardness, strength, high thermal resistance, high wear
resistance and lower density[1][2]. Specifically aluminum
metal matrix composites have preferred in industry such as
automotive, aeronautics and marine industries for obtaining
best result of mechanical properties. Most of the Composite
materials are manufactured through either liquid metallurgy
or solid method. In case of liquid metallurgy method,
electromagnetic stir casting method, stir casting method,
and in-situ method and centrifugal cast. Depending on the
Matrix material, it can be classified as Polymer Matrix
IJISRT20MAY368 www.ijisrt.com
International Journal of Innovative Science and Research Technology
Shashikanth G S
Asst. Professor
Department of Mechanical Engineering
Nagarjuna College of Engineering and Technology
Bengaluru, Karnataka, India
Composite (PMC), Metal Matrix Composite (MMC) and
Ceramic Matrix Composite (CMC) [2][3][4].
Aluminum alloys are having good thermal
conductivity with lightweight in nature. But, specifically
for heat exchanger applications thermal conductivity of
aluminum alone may not be suitable for manufacture.
Hence to improve the thermal conductivity property one of
the possible idea is Metal Matrix Composites (MMC)
fabrication process with high thermal conductivity
materials as reinforcement. Many authors Suggested
copposite materials are good choice due to their inherent
property of high strength-to weight ratio[1]-[5].
The fabrication techniques of MMC‘s play a major
role in the improvement of the mechanical and Tribological
properties. They will be distorted plastically and reinforced
by a range of ways principally by obstructing the
movement of linear defects referred to as dislocations on a
microscopic scale. Once movements of dislocation are
deadlocked, deformation rate is reduced that on the
opposite hand leads to strengthening or strain hardening in
order that the mechanical properties like tensile and
compressive strengths, hardness, toughness, stiffness etc
are improved. Metal matrix may be aluminum and its
alloys, Copper and its alloys, titanium and its alloys,
magnesium and its alloys and Nickel based super alloys etc.
They're appropriate where the working temperatures are
very harsh or high.
Many researchers shown Aluminium2024 Metal
matrix composites (MMC‘s) provides better performance
for heat treatment, reinforcing various ceramic material,
and various manufacturing processes, various process
parameters for improving the mechanical, thermal and
corrosion related properties. Aluminium 2024 MMC‘s
utilize ceramics like Al2O3, TiB2, TiO2,SiC, Tic, B4C,
Graphite powder ,Carbon Nano particles ,E-glass fibers,
Fly ash ,Red mud with individual and multiple primary
CuAl2 b-phase in Al-40 Cu alloy. Development of
microstructure during spray forming of Al—CU alloys is
discussed it light of the solidification behavior of droplets
and spray deposits. particulate reinforcements like Hybrid
Metal matrix composites Al2024 MMC‘s reinforced in
various Wt. % and various particle size.
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Volume 5, Issue 5, May – 2020
Al2024 metal matrix composites shows various
benefits over monolithic materials including higher specific
strength, high strength to weight ratio and corrosion
resistance, good wear resistance, higher thermal
conductivity, lower coefficient of thermal expansion.
In this paper the study of mechanical properties and
structural characterization of the Al-Zn alloy is discussed.
The entire work is divided two parts. First preparation of
the metal matrix composite by varying reinforcement
particles 10%, 20% and 30% by using liquid metallurgy
technique. Next characterize the prepared composite for
their mechanical properties such as tensile test, hardness
test, chemical composition wear and Density as per ASTM
standards.
The rest of the paper is organized as follows: Section
II discusses literature survey. In section III Methodology
used to in the paper is discussed. Section IV discusses
Various Testing procedure is discussed. Section V depicts
the results and analysis. The paper concludes in Section VI.
II. LITERATURE SURVEY
In [1] Author provides idea of Aluminum–Graphene
Nano platelets composite based casting process is
discussed. They used semi-powder method with hot
extrusion method. They used 0.25%, 0.5%, 1% of weight of
aluminum is mixed with grapheme. The result shows GNP
Nano- particle integration provides better performance for
tensile, hardness test. In [2] Metal Matrix Composites
(MMC) of Graphene /aluminum based method is proposed.
They used Friction Stir Processing(FSP) for fabrication
process. The result shows using FSP graphene aluminum
matrix composite successfully mixed. Also thermal
conductivity of graphene/ aluminum mixture is increased
compared to aluminum matrix. In [3] stir casting method
based production of particulate composite plate method is
discussed. They used Al alloy as a matrix phase and
reinforcement is alumina (Al2O3). The results shows
better performance. In [4] Aluminum and Silicon alloy
based scheme is discussed. In [5] friction stir alloying
based bulk aluminum-graphene nano platelets composite
fabrication process is discussed. They fabricated channel
on surface of cross section of the aluminum plate and filled
with graphene nano platelets Further, cross-sectional
surface is covered by same size of another aluminum plate,
The friction stir alloying method is used. The results of
tesile and hardness test provides better performance.
In this paper Aluminum -Zinc alloy based structural
characterization and mechanical properties are studied. The
various metal matrix composite for the dfferent
reinforcement particles 10%, 20% and 30%. Further to
study the performance tests such as tensile test, hardness
test, chemical composition wear and Density tests are
carried out as per ASTM standards
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International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
III. METHODOLOGY
Fig 1:- The methodology of the whole experiment involves
Fig 1 shows Methodology used in the works. Initially
AI-Zn is prepared. Then Test such as Rockwell and Brinell
hardness test, Tensile test, density test, wear test is carried
out.
IV. SAMPLE PREPARATION
The process of casting starts with placing empty
crucible in the furnace. Then in order to maintain
homogeneous mixture temperature of the heater is
gradually increased up to 800°C. In the pre processing dust
particles present in Aluminum alloy removed and weighed,
charged in the crucible for melting. Further required
quantities of reinforcement Zinc are weighed on the
weighing machine. Reinforcements are heated for 45
minutes at a temperature of 500°C. When matrix was in the
semisolid stage condition at 650°C, some amount of D gas
master alloy can be added weighed by weight is use as
wetting agent. After five minutes alloy forms completely
dissolve of impurity on liquid surface which to be removed.
Each melt was stirred for 30s after the addition of the
modifier, held for 5 min and then poured into a cubical
graphite mould surrounded by fireclay bricks. Heater
temperature is then gradually increased to 800°C. At this
heater temperature stir sometimes is started and continued
for five minutes. as Casting and Centrifugal Casting .
Material
Sl. No. Al (in gms) Zn(in gms)
Composition
1 Al - 10% Zn 900 100
2 Al - 20% Zn 800 200
3 Al - 30% Zn 700 300
Table 1:- Composition of Al-Zn alloy
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Volume 5, Issue 5, May – 2020
 Cutting:
After obtaining the composition from the casting
process, specimen of desired dimension is prepared to
conduct the testing process by using some with the help of
cutting tools. Further the specimen of composition of alloy
fixed in the lathe to remove the material and to get the
desired shape to conduct the test. The cast samples used are
approximately of same width, length and height .
 Tensile specimen:
The casting samples were prepared by some
dimension of squared shaped pieces. By using EDM cutting
machine, the tensile specimens were prepared to conduct
the tensile properties. Below figure shows the specimen
dimension required to conduct the test.
R4
4 liquid, and solid comical components. Chemical analysis
4 materials analysis, nanotechnology, environmental and
m 4
3 clinical chemistry etc. chemical composition of a material
25
Fig 2:- Tensile test specimens in cm
 Wear Test:
The casting samples were prepared by some
dimension of squared shaped pieces. By using Cutting tools
or by turning lathe the specimen were prepare to conduct
the wear properties. Test samples are prepared as per
ASTM standards. AISI1020 round rods of diameter 1cm
and 10cm are taken and cut in to cylinders of required
lengths as per ASTM standards. Below figure shows the
specimen dimension required to conduct the test.
International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
V. RESULTS AND DISCUSSION
 Various Testsconducted
The following tests were conducted to assess the
properties of the composites produced:
 Density test-to determines the weight in Air and weight
in water.
 Hardness test-to determines the hardness of the
prepared specimen by using Rockwell & Brinell‘s
hardness test.
 Wear test- to determine wear on the prepared specimens
by using pin on disc wearing test machine.
 Tensile test- to determine tensile strength.
 Chemical Composition
The equipment of Chemical analyzer instrument used
to identify, quantify and characterize the samples of gas,
instruments are used in wide verity of applications such as
analysis accuracy provides better understanding of the
information of component and helps solving chemical
problem, Research and Development. It also helps to
ensure the quality of a chemical formulation.
Table 2 Shows weight percentage of different element
present in the Al-Zn samples. The list indicates both as
casting and centrifugal casing to determine average value
of AI and average value of Zn. Figure3 shows Al -10%,
20%and 30% Zn As Casting Samples.
Al-Zn Alloy

 Hardness Test: Average Average

Sl.No As casting
The casting samples were prepared by some value of Al value of Zn
dimension of squared shaped pieces. By using milling 1 Al90% Zn 10% 90.83 8.68
machine or by cutting tools to polish the face of all the
surface of the specimens by using sandpaper were prepare 2 Al80% Zn 20% 82.66 >16.82
to conduct the Hardness test. Test samples are prepared as
per ASTM standards. AISI1020 length is 5cm and width is 3 Al70% Zn 30% 74.26 >25.18
2cm are taken as per ASTM standards.

 Density Test: Average Average

Centrifugal casting
The casting samples were prepared by some value of Al value of Zn
dimension of squared shaped pieces. By using milling
machine or by cutting tools to polish the face of all the
1 Al90% Zn 10% 90.95 8.56
surface of the specimens by using sandpaper were prepare
to conduct the Density test. Test samples are prepared as 2 Al80% Zn 20% 82.66 >16.82
per ASTM standards. AISI1020 length is 5cm and width is
2cm are taken as per ASTM standards. Below figure shows 3 Al70% Zn 30% 72.27 >26.31
the specimen dimension required to conduct the test. Table 2:- Average value of aluminum and zinc for the
Weight percentage of Al-Zn samples

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Volume 5, Issue 5, May – 2020
Fig 3:- Al -10%, 20%and 30% Zn as Casting Samples
 Density Test
It is relationship between the die preheating
temperature and density of composites. The density of
reinforced composite of aluminum and zinc particles is
greater than the density of unreinforced Al alloy at 35°C
die preheating temperature. Further, the density of
International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
composites increased with an increase in weight fractions
of reinforcements. The density of Al alloy and composites
decreased on increasing the die preheating temperature due
to slower cooling rates. At lower cooling rate, dendrite arm
spacing of matrix was increased which resulted in reduction
of density. This causes increase in porosity of aluminum
alloy composites. The density of aluminum and zinc weight
ratio particles reinforced composite decreased by
composition which was equal to weight on increasing the
die preheating temperature from 35 to 250°C. This could be
attributed to increasing in the size of eutectic silicon phase
because of the longer solidification time. The porosity of Al
alloy and composites increased with an increase in die
preheating temperature. A decrease in density of Al alloy
and composites resulted in increased porosity level on
increasing the die preheating temperature. The low porosity
level was observed for Al alloy compared to composites at
all the temperatures studied.

Weight in
Composition Alloy Trial No. Weight in AIR Density Average density
WATER
Al 70 %-Zn30% 1 14.515 10.234 3.3906
3.388
As Casting 2 12.338 8.693 3.3849
Al 80 %-Zn20% 1 12.025 7.628 2.7348
2.803
As Casting 2 13.058 8.511 2.8718
Al 90 %-Zn10% 1 11.645 6.466 2.2485
2.31
As Casting 2 11.799 6.823 2.3712
Al 70 %-Zn30% 1 13.733 9.625 3.343
3.338
Centrifugal Casting 2 13.246 9.272 3.3332

Al 80 %-Zn20% 1 12.863 8.321 2.832

2.792
Centrifugal Casting 2 13.638 8.681 2.7513
Al 90 %-Zn10% 1 11.854 6.823 2.3562
2.298
Centrifugal Casting 2 11.458 6.342 2.2396
Table 3:- Average value of aluminum and zinc for the Weight percentage of Al-Zn samples.

Fig 4:- Histogram showing values of YS for different Al-Zn alloys

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Volume 5, Issue 5, May – 2020 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
 Hardness Test Illustration of Hardness test can be obtained by
The Brinell hardness tester used to test hardness the
material. The ASTM E8 standard used with the 2P
specifications of ball indenter diameter 10mm, load of 500 Ball πD D- √ D 2 – d 2
kg and 30 seconds is applied. The test is performed in room
temperature (30°C to 32°C) and hardness measurements is
taken from five different places on each sample and then D = Ball diameter ( here D=10mm is cosidered)
average hardness value is considered. d = impression diameter
F = load
BHN = Brinell Hardness Number

Composition Sl.No Trails BHN

1 1
Al-10%Zn As Casting 2 2 63.9983
3 3
1 1
Al-20%Zn As Casting 2 2 93.46929
3 3
1 1
Al -30%Zn As Casting 2 2 108.9091
3 3
1 1
Al-10%Zn Centrifugal Casting 2 2 67.60236
3 3
1 1
Al-20%Zn Centrifugal Casting 2 2 99.27509
3 3
1 1
Al -30%Zn Centrifugal Casting 2 2 117.3351
3 3
Table 4:- Test of Brinell hardness number of different Al-Zn alloys.

200 BHN

Fig 5:- shows the variation of hardness number of Al-10% Zn, Al-20% Zn and Al-30% Zn with zinc percentage.

Fig 6:- Aluminum -Zinc Alloy of As Cast & Centrifugal Casting Specimens trails for Brinell hardness test

From the calculation and graphs, it is clear that there is an increase in the hardness of the aluminum–zinc metal alloy
composite. So, as the percentage of Zinc reinforcement increases the hardness of the composites also increases and this is useful
for aerospace application and automobile industries.

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Volume 5, Issue 5, May – 2020 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
Composition Sl.No Trails RHN
1 40
Al -10%Zn As Casting 2 39 40
3 41
1 51
Al -20%Zn As Casting 2 61 59.7
3 67
1 62
Al -30%Zn As Casting 2 64 64
3 66
1 46
Al -10%Zn Centrifugal Cast 2 50 48.3
3 49
1 60
Al -20%Zn Centrifugal Cast 2 61 61
3 62
1 61
Al -30%Zn Centrifugal Cast 2 67 65.7
3 69
Table 5:- Rockwell Hardness number of different Al-Zn alloys

Fig 7:- variation of hardness number of Al-10% Zn,Al-20% Zn and Al-30% Zn with zinc percentage.

Fig 8:- Al-Zn Alloy of As Cast & Centrifugal Casting specimens trails for Rockwell Hardness Test

 Wear Test
Two specimens are essential to perform pin-on-disk wear test. First, a pin with a radius used tip, is positioned perpendicular
to the other, usually a flat circular disk. A ball, rigidly held, is often used as the pin specimen. The test machine causes either the
disk specimen or the pin specimen to revolve about the disk centre. In either case, the sliding path is a circle on the disk surface.
The plane of the disk may be oriented either horizontally or vertically.

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Volume 5, Issue 5, May – 2020 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165

Composition Co-efficient M3/Nm Average Co-efficient

7.01E-08
Al -10%Zn As Casting 3.50E-08 1.51E-07
3.47E-07
1.82E-07
Al -20%Zn As Casting 3.19E-08 2.62E-07
5.73E-07
1.21E-07
Al -30%Zn As Casting 3.82E-08 6.69E-08
4.14E-08
1.94E-07
Al -10%Zn Centrifugal Cast 3.79E-07 3.85E-07
6.69E-08
2.74E-07
Al -20%Zn Centrifugal Cast 7.01E-08 2.17E-07
3.06E-07
9.56E-08
Al -30%Zn Centrifugal Cast 7.65E-08 7.01E-08
3.82E-08
Table 6:- Experimental values of wear of Zn alloys at different applied loads

 Tensiletest
The tensile test is one of the most widely used of the
mechanical tests. The tensile tests were carried out
according to the ASTM E8 standard by universal testing
machine to determine the amount of tensile strength to
withstand during fracture. A tensile test of a material is
performed on ductile materials.

A. Aluminum reinforced with 10% Zinc Centrifugal

Casting
Fig 9:- Variation Al-Zn alloys with Wear rate

Fig 10:- Al-ZnAs Casting Wear Rate

Fig 11:- Stress vs Strain for 10% Zn with Aluminium
Alloy.

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Volume 5, Issue 5, May – 2020
Table 7:- UTM Results for Al-10%Zn Centrifugal Casting
B. Aluminum reinforced with 20% Zinc As Casting
The ultimate tensile strength and total elongation for
the Al-10% Zn were found to be 208.374MPa and 5 %
respectively. The ultimate Strength was calculated to be
77.307.
Fig 12:- stress vs Strain for 20% Zn with Aluminium Alloy
IJISRT20MAY368
International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
Table 8:- UTM Results for Al-20%Zn As Casting
The ultimate tensile strength and total elongation for
the Al-20% Zn were found to be 219.212 MPa and 16.24 %
respectively. The ultimate load was calculated to be 3.507
KN.
C. Aluminum reinforced with 30% Zinc As Casting
Fig 13
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Volume 5, Issue 5, May – 2020
Table 9:- UTM Results for Al-30%Zn As Casting
The ultimate tensile strength and total elongation for
the Al-30% Zn were found to be 231.928 MPa and 10.6 %
respectively. The ultimate strength was calculated to be
103.653MPa.
Fig 14:- Al-10% Zn Centrifugal Casting
Fig 15:- Al-20% Zn as Casting
Fig 16:- showsAl-30% Zn as Casting
VI. CONCLUSIONS
In this paper Aluminum 2024 alloy reinforced with
Zinc synthesized by As casting and Centrifugal casting
process with different weight fraction of 10%, 20% and
30% is discussed. The mechanical properties such as tensile
strength, hardness test, density and wear test. And some
chemical composition by using scanning electron
microscope test were obtained and analyzed. Result shows
Zinc of 10%, 20%, 30% reinforced with Al2024
composites hardness value maintaining optimum value. The
results show that wear loss of the Al-Zn composite
decreases and the damaged surfaces look smoother with
increasing the Zinc particle size. Also the wear rate of Al-
IJISRT20MAY368
International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
Zn composites initially decrease slightly by increasing
sliding speed and after a critical speed, wear rate changes
dramatically.
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